Gefran GFX-4 Data Sheet

Main application

• Packaging

• Extrusion

• Thermoforming

• Injection moulding

• Textile

• Multizone furnaces

GFX-4

4 LOOP MODULAR POWER CONTROLLER

Main features

4 independent loop control unit.
Compact, ready to use, equipped also with
fieldbus interface.

Unit consisting of:

• Controller

• 30, 60, 80kW solid state relay

• Current transformers (one or four)

• Fuses-holder (option)

• 4 universal main inputs

• 4 heat/cool independent PID

• 4 main output internally wired to the SSR

• 4 auxiliary analog inputs (option)

• 4 configurable output (option):
relay / logic / TRIAC / continuous

• 2 configurable relay alarm output

• 2 digital inputs

• Standard digital communication:
Modbus RTU

• Optional Fieldbus communication:
Profibus DP, CANopen, DeviceNet,
Modbus RTU, Ethernet Modbus TCP,
Ethernet IP, EtherCAT, ProfiNET

• DIN rail or panel mounting

PROFILE

GFX4 is a four independent loop control­ler, designed to manage electrical power.
GFX4 is a compact unit bounding different
technological elements like:

• controller

• solid state relay

• current transformers

• fuses-holders (option)
The final result is a cost saving in terms of
space and cabling.
GFX4 consisting of:

• power management unit

• analog and digital inputs,

• analog and digital outputs

• standard digital communication

• integrated solid state relays

• fuses-holder (option)
Geflex controls autonomously the four
loop controllers, furnishing a complete
diagnostics like the loaded current, the
control of the zones, the alarms state.
A specific step by step software tool has
been develop in order to assist the pro­duct configuration based on the different
applications.
Communication with the outside is of pri­mary importance.
Geflex dialogs with the operator terminals
according to the most popular protocols:
from the simple and efficient Modbus to,
by a second optional fieldbus communi-

cation, the by-now indispensable Profibus
DP, CANopen, DeviceNet, Modbus RTU,
Ethernet Modbus TCP, Ethernet IP,
EtherCAT, ProfiNET.

The product’s furnished with a standard

configuration, simple and quickly to modify.
The assignment of different functions to
the outputs is very simple.

MODELS

(see table in order code)

3 different sizes, depending on the elec­tric power managed, are available.

GFX4 80
Maximum contemporaneous power up to
80kW@480V.
Each zone could reach up to 19,2 kW.
This limit could be extend to 23,7 kW
using the “smart power management”
(not all the zone contemporaneous).
Nominal current 40A for zone, not con­temporary maximum 57A

GFX4 60

Maximum contemporaneous power up to
60kW@480V.
Each zone could reach up to 15,3 kW.
Nominal current 32A for zone
Fuse holder could be provide as an
option.

GFX4 30

Maximum contemporaneous power up to
30kW@480V.
Each zone could reach up to 7,6 kW.
Nominal current 16A for zone
Fuse holder could be provide as an
option.

INPUTS

Process analogue

4 universal process input could accept:
thermocouple, thermoresistance, current
and tension linear.
The type could be choose by software
and no external converting device are
required.

Digital

2 digital input.
The functionality could be selected within
a wide range including setpoint selection,
MAN/AUTO, alarm memory reset and
many other.

Incorporated CT

From 1 to 4 CT control each zone and the
relative alarm control is start up (HB..).

Auxiliary analogue (option)

4 further analogue inputs are available,
typically for external current transformer
reading.

OUTPUTS

By default a different meaning is applica­ble.

POWER

Power is controlled with double SCR in
anti-parallel, zero crossing switching prin­ciple, with configurable proportional cycle
time.
Different load connection are available:
monophase, dualphases, three-phases.

FUSES (option)

The fuses are orderable on the GFX4
30KW and 60kW model.
Thanks to this, you save time, wiring is
simplified, and dimensions in the panel
are reduced.

PROGRAMMING

The Geflex modules can be programmed:

• using GFX-OP

• using Winstrum tool software

• using Industrial PC or PLC.

The software can be used to define the
state of alarm outputs or a preset power
level to be supplied in case of broken
probe.
This assures continuity of service in the
individual zone.

Tuning

• Self-tuning:
calculation of PID parameters at system art.

• Auto-tuning continuous: continuous
adjustment of PID

• Autotuning one-shot: output modulation
and event-driven automatic PID parame­ters re-calculation

Special functions

• Soft-start: power parcellization time­based

• Software Off: disabling of the control,
outputs are turned off

• Inputs\outputs: direct management of
inputs/outputs, independently from inter­nal firmware

• Simulation of four independent Geflex
units.

Output alarms configurable via software.

Heating control

For each zone an heating control internally
connected to power unit is present, then
no further connections needed between
power unit and controller.

Cooling control (option)

For each zone a cooling control is present
4 types of outputs are available: relay,
logic, triac, continuous. A current transfor­mer is furnished with TRIAC output.

Alarms

Two relay output configurable as minimum
and maximum alarm are available for each
unit.

LEDs

Eight monitoring led are available in order
to provide diagnostic information.

RN
RUN stet of the CPU
ER
Error
DI1
DI1 digital input state
DI2
DI2 digital input state
O1
Outupt 1 state
O2
Outupt 2 state
O3
Outupt 3 state
O4
Outupt 4 state

FUNCTIONS

Control

The Geflex control algorithm works with
any type of thermal process.
Different control modes are available: from
a simple ON/OFF control to PID single or
double acting heat/cool (for cooling, simply
indicate the fluid used).
Sophisticated and efficient automatic
tuning algorithms for control parameters
provide precise process control without
the presence of an operator.

Alarms

There are 8 alarm assignable to each
single canal or to all (AND / OR logic) and
configurable as absolute, relative, direct,
reverse, window, latching or not, inhibit at
power-on.

Diagnostics

Geflex assures efficient process monito­ring from a thermal and electrical point of
view, allowing the operator to foresee bre­akdowns or malfunctions and take timely
action (for example, in case the tempe­rature safety limit is exceeded, broken
probe, load fault).
The LBA alarm precisely checks the con­trol loop, while the on-board current tran­sformer (one always present, four availa­ble in option) lets you directly monitor load
and trip the HB alarm in case of current
failure or SSR in short circuit.
Detection of short circuit or opening of
input probe, open loop alarm (LBA), inter­rupted load alarm (HB).
Over temperature alarm

STANDARD DIGITAL
COMMUNICATION

The product is furnished with standard
digital communication [PORT 1] used as
GFX4 connection to a HMI or Industrial
PC.
Also by a dedicated connector (10 pins)

it’s possible to connect the actual range

of Gefllex.
A second standard digital communication
(PORT 2) configurable by most popular
protocol:
CANopen
DeviceNet
Profibus DP
Modbus RTU
Ethernet Modbus TCP
Ethernet IP,
EtherCAT,
ProfiNET

is available as option.

Net address

Assigned by two rotative selectors.

GENERAL DESCRIPTION

3

4

5

13

6

2

12

1

7

11

10

8

9

8

14

1. DIN rail frontal

2. power terminal: screws

3. power terminal

4. ventilation grid (attention NOT obstruct)

5. hook/release device back DIN rail

6. hole for screws

7. microswitchs of configuration

8. standard digital communication

9. rotative selector switch

10. connectors J1, J2, J3, J4

11. fuses-holder (only for 30KW and 60KW models)

12. fuses-holder terminal (F1, F2, F3, F4)

13. power terminal (U1, U2, U3, U4)

14. ventilation grid (attention NOT obstruct)

DIMENSIONS - INSTALLATION

82

109,5

92,5 35 19,5

92,5 35 19,5

147

140

4

140

140

147

42140

140

111,5

182

195

101,5

109,5

4132

101,54

132 4

TECHNICAL DATA

INPUTS

IN1...IN4 [process analog inputs]

Connector: J4

Function
default process variable (configurable)
Sampling time
120msec the four inputs
Accuracy
0,2% FS ±1 steps at 25°C. (16000 points)
Thermal drift
0,005% FS/°C
Type

• Thermocouples ITS90:

J, K, R, S, T, custom (IEC584-1, CEI EN
60584-1, 60584-2).
Internal cold junction compensation with
automatic compensation.
Selectable temperature range: °C/°F

• Thermoresistance: Pt100 DIN 43760

Max. resistance 20Ω

Selectable temperature range: °C/°F

• Voltage: range 0/12...60mV, Ri > 1MΩ

0/0,2…1V, Ri > 1MΩ custom 60mV at 32

sections

• Current: range 0/4...20mA , Ri = 50Ω
custom 20mA at 32 sections

IN5...IN8 [auxiliary analogue inputs]
Connector: J3

Function
default analog inputs reading
Sampling time
480msec for TC, voltage
Accuracy
1% FS ±1 steps at 25°C.
Type

• Thermocouple ITS90:

J, K, R, S, T, custom (IEC584-1, CEI EN
60584-1, 60584-2).
Internal cold junction compensation with
automatic compensation.

• Voltage:

range 0/12...60mV, Ri > 1MΩ

OUTPUTS

OUT 1...4 [heating control]

outputs connected to solid state relay

Function
default heating control (configurable)

OUT 5...8 [cooling control]
Connector: J1

Function
default cooling control (configurable)
Type

• Relay: NO, max 3A, 250V/30Vdc,
cosϕ = 1, resistive load

• Logic: 24Vdc, 35mA

• Continuous:

• voltage: 0/2...10V, ±10V, max 25mA
short circuit protection

• current: 0/4...20mA, 500Ω max

• insulation: 3500V

• Triac: 230V/4Amp AC51
(1A for four)
(2A for two)

OUT 9...10 [alarms]
Connector: J1a/J1

Function
default alarms (configurable)

Type
Relay: NO, max 5A, /30Vdc, cosϕ = 1

LEDs

RN .............RUN state of the CPU

ER..............error

DI1 .............DI1 digital input state

DI2 .............DI2 digital input state

O1 ..............Out.1 main input state

O2 ..............Out.2 main input state

O3 ..............Out.3 main input state

O4 ..............Out.4 main input state

Protocol
Modbus RTU _______57,6Kbps
CANopen __________10K...1Mbps
Profibus DP ________9,6...12Mbps
DeviceNet _________125K...500Kbps
Ethernet Modbus TCP,
Ethernet IP 10/100Mbps
EtherCAT 100Mbps
ProfiNET 100Mbps

See accessories

MICROSWITCHES

8 dip switches are available to select
wiring mode and different functionalities.

POWER

SSR [integrated power element]

Rated voltage: 480Vac
Work voltage range: 24...530Vac
Non-repetitive voltage: 1200Vp
Switching voltage for zero: < 20V
Rated frequency: 50/60Hz (self-adjusting)
Rated current AC51
GFX-4 30kW: 16Amp
GFX-4 60kW: 32Amp
GFX-4 80kW: 57Amp
Non-repetitive overcurrent [t=20msec]
GFX-4 30kW: 400A
GFX-4 60kW: 600A
GFX-4 80kW: 1150A

2

I

t for melt [t=1...10msec]
GFX-4 30kW: 645A
GFX-4 60kW: 1010A
GFX-4 80kW: 6600A

2

s

2

s

2

s
Dv/dt critical with deactivated output:
1000V/μsec
Rated insulation voltage In/Out: 4000V

GENERAL FEATURES

Power supply:
24Vdc ±25%, max 8VA

IN9...IN12 [internal CT input]
Connector: internal connection

Function
default internal CT reading
Sampling time
60msec for CT
Accuracy
1% FS ±1 steps at 25°C.
Type

internal CT: 50mAac, 50/60Hz, Ri = 10Ω

DI1, DI2 [digital inputs]
Connector: J2

Function
default not enable (configurable)
Type
PNP, 24Vdc, 8mA (isol. 3500V)

COMMUNICATION PORTS

PORT 1 [local bus]

Connectors: S1 / S2 / S3

Function: local bus
Protocol: Modbus RTU
Baud Rate: 19,2Kbps (default)
setting 1,2...57,6Kbps
Node address: setting by double rotative
selector
Connector S1 / S2: 2xRJ114/4, RS485 2
wires insul. 1500V
Connector S3: 10 pins for flat cable

SERIAL 2 [fieldbus]
Connectors: S4 / S5
Function external fieldbus

Protection class: IP20

Working temperature range: 0...50°C
(see dissipation curves)

Storage temperature range: -20...+70°C

Relative humidity: 20...85%
UR non-condensing

Installation: EN50022 DIN rail or panel
by screw

Dimensions: see dimensions and instal­lation

Weight:
models 30/60/80 = 1200g.

models 30/60 with fuse holders = 1600g.

ELECTRICAL CONNECTIONS

Triac Logic/continuous Relay

Load 1

Load 2

Load 3

Load 4

POWER SUPPLY

+24Vdc

c (OUT 5...8)

OUT 5

OUT 6

OUT 7

OUT 8

OUT 9

OUT 10

18...32Vdc

IN 5

IN 6

IN 7

IN 8

IN 1

IN 2

IN 3

1

no

no

no

no

c

no

c

no

6

J1a

9

Green

Red

Yellow

Yellow

Yellow

J1

9

1

J2

7

1

4

+VI

3

Tx/Rx­Tx/Rx+

GNDI
+VI

Tx/Rx­Tx/Rx+

GNDI

S1

S2

Port 1

2

1
4

3
2

1

S3

Yellow

Yellow

Yellow

J3

12

1

S4

Port 2

S5

J4

power

Model

max current

F1 F2 F3 F4

U1 U2 U3 U4

IN 4

Model without fuses-holder

30kW

16A

12

60kW

32A (30A)*

F1 F2 F3 F4

U1 U2 U3 U4

Model with fuses-holder

80kW

57A (40A)*

rigid

flexible

* UL certification

0,2 - 6mm

0,2 - 4mm

0,25 - 4mm

0,25 - 4mm

0,5 - 0,6Nm 0,5 - 0,6Nm 1,2 - 1,5Nm

2

2

24-10AWG

24-10AWG 0,2 - 4mm

2

23-10AWG 0,25 - 4mm

2

23-10AWG 0,25 - 4mm

0,2 - 6mm

2

2

24-10AWG 0,5 - 16mm

24-10AWG 0,5 - 10mm

2

23-10AWG 0,5 - 10mm

2

23-10AWG 0,5 - 10mm

2

2

2

2

20-6AWG

20-7AWG

20-7AWG

20-7AWG

ORDER CODE

Model GFX4

30

(4x16A)

60

(4x32A)

(4x30A)*

80

(4x40A)

* Certification UL

Current (Amp) Voltage (Vac) Power (kW)

max for channel range nominal working

110 (4x16x110) 7 (16x110) 1,7 (1x16x110) 1,7

16 24...530 480

32 (30)* 24...530 480

40* 57 24...530 480

230 (4x16x230) 14,7 (16x230) 3,6 (1x16x230) 3,6

400 (4x16x400) 25,6 (16x400) 6,4 (16x400) 6,4

480 (4x16x480) 30,7 (16x480) 7,6 (1x16x480) 7,6

110 (4x32x110) 14 (32x110) 3,5 (32x110) 3,5

230 (4x32x230) 29,4 (32x230) 7,3 (1x32x230) 7,3

400 (4x32x400) 51,2 (32x400) 12,8 (1x32x400) 12,8

480 (4x32x480) 61,4 (32x480) 15,3 (1x32x480) 15,3

110 (4x40x110) 17,6 (40x110) 4,4 (1x57x110) 62,7

230 (4x40x230) 36,8 (40x230) 9,2 (1x57x230) 13,1

400 (4x40x400) 64 (40x400) 16 (1x57x400) 22,8

480 (4x40x480) 76,8 (40x480) 19,2 (1x57x480) 27,3

total

contemporary

single

channel

GFX4

max for

single channel

NOMINAL POWER

30KW 30

60KW 60

80KW 80

AUXILIARY OUTPUTS

Absents O

Relay R

Logic D

Continuous C

Triac T

FIELDBUS

O Assente

M Modbus RTU

P Probus DP

C CANopen

C1 Euromap 66

D Device Net

E Ethernet Modbus TCP

E1 Ethernet IP

E2 EtherCAT

E4 ProNET

E5 Real Time Ethernet

FUSES

O Absent

F Fuses-holder + fuses extrarapid (*)

1 1 Current Transformer

2 4 Current Transformers

3

(*) Available only for 30, 60kW power

4

(**) Option NOT available with Fieldbus E1 or E2 or E4 or E5

GEFRAN spa reserves the right to make aesthetic or functional changes at any time and without notice.

AUXILIARY INPUTS

1 Current Transformer + 4 Linear
inputs

4 Current Transformers + 4
Linear inputs (**)

Conformity TC N° RUД-IT.AЛ32.b.01762

CSA

UL

Conformity C/CSA/US CoFC no. 70043834

Conformity C/UL/US File no. E243386

The instrument conforms to the European Directives 2004/108/CE and 2006/95/CE with reference to the generic standards:

EN 61326-1 (Product) EN 61010-1 (safety)

DTS_GFX4_10-2015_ENG